Methods and Apparatus for Transporting, Storing and Dispensing Oilfield Chemicals

ABSTRACT

A method and system for chemical transportation, storage, and dispensation, which provides a base with ISO mounts for enabling a ISO tank, van container, screw conveyor, or the like to be carried thereon. The base accommodates either or both of “roll off” or “hooklift hoist” technologies to allow easy loading and unloading. A first end of the base is carried by one or more rollers, and the underside is structured to allow rolling of the base on the bed or rack of the transport vehicle. After unloading the base with its ISO cargo, the transport vehicle leaves the well site and is free to retrieve another ISO tank or container as appropriate, thereby lowering the tractor-trailer capital requirements to support fracturing operations. Weigh scales allow the weight of the ISO container to be determined to allow the operator to monitor the inventory of chemicals as they are used.

TECHNICAL FIELD

The present disclosure relates generally to oilfield equipment and inparticular to surface equipment for supporting fracturing operations.

BACKGROUND

Well site locations for oil and gas wells have become increasinglycongested, particularly as enhanced recovery techniques have beendeveloped. After drilling operations have finished and during wellcompletion operations, a well site may generally include a wellhead,blowout preventers, hydraulic fracturing and proppant systems, pumps,generators, water storage, transfer and treatment equipment, andchemical and proppant storage containers. Other equipment associatedwith drilling, completing, and/or producing wellbore may also beprovided at the well site location.

Modern enhanced recovery techniques may result in multiple wellheads ata single well site and/or wellbores with multiple lateral branches.Hydraulic fracturing operations utilized in enhanced oil and gasrecovery, for example, may generally include raw materials forpreparation of fracturing fluid, a blender system, a pump system, aswell as transfer equipment. In the past, a fracturing operation for asingle well might take three to ten days, after which, the fracturingequipment was removed. However, now with multiple wellhead per well siteor multiple lateral branches extending from a primary wellbore beingmore common, fracturing equipment may remain at a single location formultiple weeks. Accordingly, there is a recognized need to reduce thefootprint of fracturing equipment at a well site.

The traditional method for transporting and storing liquid or drychemicals on location at a well site is by conventional tractor/trailer,flatbed trailer, or bobtail truck.

Prior to delivery to a well site, large quantities of required liquidchemicals are loaded into one or more tanker trailers. In some cases,large volumes of liquid chemical are supplied in International StandardsOrganization “ISO” specified tanks—chemical tanks contained inside a 20ft. by 8 ft. by 8.5 ft. frame with standardized mounting locations. ISOtanks are attached to a semi-trailer specifically designed to accept ISOframes. Smaller volumes of liquid chemicals are typically loaded intotes and carried on flatbed trailers. The tanker trailers and flatbedtrailers are then transported to the well site, where they remain parkedfor the duration of the fracturing job or until the tanks are emptied.

The liquid chemicals are typically dispensed directly from the tankertrailers, ISO tanks, and totes during the fracturing job. Inlarge-volume chemical operations, the chemical inventory is typicallymonitored manually by dipstick, but in some cases, an electronic fluidlevel device may be available. In small-volume liquid chemicaloperations, the chemical inventory is usually monitored by dipstick, orin some instances, by weigh scales.

In the case of dry chemicals, large volumes of dry chemicals aretraditionally supplied in “big bags”—approximately 4 cubic foot bagswith a bottom drawstring outlet. Big bags are typically transported fromthe supplier to the well site by a tractor-trailer. Small volumes of drychemicals are commonly packaged in sacks or bags, for example 50 lb.bags. The bags are transported to the well site on flatbed trucks ortractor-trailers and stored there for the duration of the fracturing jobor until the load is used up. Dry chemicals are susceptible to moistureand must be covered while stored in inclement weather.

To dispense, big bags are suspended by a crane over a screw feeder atground level, and the dry chemical is gravity fed into the screw feederhopper to be introduced into the fracturing blender system. Small bagsare transferred manually from the truck or trailer to a metering feederon a fracturing blender as required by the fluid system being mixed. Inlarge or small volume dry chemical operations, the inventory ismonitored by counting the bags of chemical used.

Accordingly, if a particular job calls for 3000 gallons each of fivedifferent liquid chemicals and a large quantity of dry chemical, therewould be five tanker tractor-trailers and at least one vantractor-trailer parked on location for the duration of the fracturingoperations, occupying at least six 8 ft. by 60 ft. footprints of padspace, or 2880 sq. ft. Similarly, in the case of smaller volume liquidor dry chemicals, a flatbed trailer with totes or small bags ofchemicals occupies another 8 ft. by 60 ft (320 sq. ft.) footprint of padspace. In addition to footprint requirements, there is a capital expenseassociated with tractor-trailers, flatbeds, and tandem axle trucks beingtied up and idle for a substantial part if not the entire duration of afracturing operation.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are described in detail hereinafter with reference to theaccompanying figures, in which:

FIG. 1 is an elevation view in partial cross section of a well siteduring completion operations that employs a hydraulic fracturing system,chemical storage units, and associated systems and equipment forsupporting fracturing operations according to an embodiment;

FIG. 2 is a perspective view of a chemical transportation, storage, anddispensation system according to one or more embodiments, showing a basedesigned to accommodate either “roll off” or “hook” portable containertechnologies adapted for carrying an intermodal shipping container onload cells;

FIG. 3 is an elevation view of the chemical transportation, storage, anddispensation system of FIG. 2, shown carrying a tank mounted within ashipping container frame;

FIG. 4 is an elevation view of the chemical transportation, storage, anddispensation system of FIG. 2, shown carrying a van container forstorage of small volume dry chemical bags;

FIG. 5 is an elevation view of the chemical transportation, storage, anddispensation system of FIG. 2, shown carrying a commercially availablescrew conveyor adapted with corner castings for dispensing large volumesof dry chemical;

FIG. 6 is an enlarged exploded perspective diagram of a quick disconnectconnector system according to an embodiment for use with the system ofFIGS. 2-5;

FIG. 7 is an enlarged perspective view of the quick disconnect connectorsystem of FIG. 6, showing a mount and connector of the base of FIG. 2received into an oval hole of a corner casting of an intermodal shippingcontainer and oriented in an unlocked position;

FIG. 8 is an enlarged perspective view of the quick disconnect connectorsystem of FIG. 7, shown in a locked position; and

FIG. 9 is a flow chart of a portion of a method for completing awellbore according to an embodiment, demonstrating use of the chemicaltransportation, storage, and dispensation system of FIGS. 1-8.

DETAILED DESCRIPTION

The foregoing disclosure may repeat reference numerals and/or letters inthe various examples. This repetition is for the purpose of simplicityand clarity and does not in itself dictate a relationship between thevarious embodiments and/or configurations discussed. Further, spatiallyrelative terms, such as “beneath,” “below,” “lower,” “above,” “upper,”“uphole,” “downhole,” “upstream,” “downstream,” and the like, may beused herein for ease of description to describe one element or feature'srelationship to another element(s) or feature(s) as illustrated in thefigures. The spatially relative terms are intended to encompassdifferent orientations of the apparatus in use or operation in additionto the orientation depicted in the figures.

FIG. 1 is an elevation view in partial cross-section of a well site 120during well completion operations according to an embodiment. Well site120 may include a well head 124, which may be fluidly connected to ahydraulic fracturing pumping system 126. According to an embodiment,well site 120 may include a chemical transportation, storage, anddispensation system 10, which may consist of one or more chemicalhandling apparatus 20, 30, for example.

FIG. 2 is a perspective view of a chemical handling apparatus accordingto one or more embodiments, and in particular of a chemicaltransportation, storage, and dispensation system 10. FIG. 3 is anelevation view of chemical transportation, storage, and dispensationsystem 10, shown carrying a tank mounted within a shipping containerframe. FIG. 4 is an elevation view of chemical transportation, storage,and dispensation system 10, shown carrying a van container for storageof small volume dry chemical bags. Referring to FIGS. 2-4, chemicaltransportation, storage, and dispensation system 10 provides a commonplatform or base 12, with mounts 14 and connectors 16 for enabling anintermodal shipping tank container 20 (FIG. 3) or van container 30 (FIG.4), for example, to be attached to the upper side 13 of platform 12. Inan embodiment, each mount 14 and connector 16 interfaces with astructural receptacle 26 located at the bottom of containers 20, 30,typically at the corners.

In one or more embodiments, base 12, mounts 14, and connectors 16 aredesigned and arranged to carry standard 20 ft. ISO shipping containers,although base 12, mounts 14, and connectors 16 may equally be designedto carry shipping containers conforming with other standards and havingother dimensions or mounting arrangements, as appropriate. In someembodiments, base 12 is no larger than 8 ft. by 60 ft.

Base 12 is ideally designed to accommodate either the “roll off” or“hooklift hoist” technologies, or both, which are associated with therefuse business and allow portable containers to be loaded and unloadedeasily. A first end 17 of base 12 is carried by one or more rollers 18,which allow end 17 to be rolled on the ground as base 12 is loaded on orunloaded from a transport vehicle (not illustrated). “Roll-off”technology employs a truck or trailer with a tiltable bed, and base 12is winched on and off the tilted bed by connection to a pad eye 22mounted to a second end of base 12. “Hooklift hoist” technology, on theother hand, employs a pivoting hydraulic hooklift hoist arm that engagesan elevated hooklift hoist attachment 32 and lifts the container onto arack that is attached to the truck or trailer frame. The underside 11 ofbase 12 may be reinforced with ribs or track (not illustrated) to allowsmooth and straight rolling of the base 12 on the bed or rack of thetransport vehicle.

According to one or more embodiments, a “roll off” truck or trailer, ora “hooklift” truck or trailer is used only for the transportation ofbase 12 with its carried ISO tank 20 or van container 30. Base 12 isunloaded at the well site and occupies a fraction of the footprintrequired by the traditional storage of a tractor-trailer on site. Forexample, for the above requirement of five 3000 gallon liquid chemicaltanks and one large quantity of dry chemical, there need only be six of8 ft. by 20 ft. ISO containers on location, occupying approximately 1000sq. ft. of pad compared to the original 2880 sq. ft.

After unloading base 12, the transport truck then leaves the well sitelocation and is free to retrieve another ISO tank or container asappropriate. Thus, a single transport vehicle with “roll off” or“hooklift” technology can support multiple ISO tanks or containers,reducing the invested capital by lowering the vehicle requirements tosupport the liquid and dry chemical operations by fifty percent orgreater over prior art methods.

As shown in FIGS. 2 and 3, according to one or more embodiments, mounts14 include or incorporate weigh scales 50 that allow the gross weight oftank container 20 to be determined. In particular, base 12 includesweight scales 50 between the ISO mounts and the surface 13 of base 12.Scales 50 allow the operator to monitor the inventory of chemicals andprovide reduction-in-weight measurement of chemicals as they are used.Scales 50 may be mechanical, or electronic using load cells, straingauges, or the like. Scales 50 may provide independent weightmeasurements, or they may provide separate quality control checks tocorrelate volumetric metering devices.

FIG. 4 is an elevation view of an arrangement for storage of smallvolume dry chemicals, in which a standard 20 ft ISO van container isattached to base 12, allowing for the weatherproof storage of the sackeddry chemicals for future use. Scales 50 may be used for inventorycontrol in addition to or in lieu of counting dry chemical sacks.

FIG. 5 is an elevation view of an arrangement for handling of largevolume chemicals. Base 12 carries an industry-standard screw conveyor 60that is outfitted with an ISO frame or mounts 62 to transport, store,and meter large volume dry chemicals to a fracturing blender mixer (notillustrated) with minimal human and weather exposure. However, bulkmaterial devices other than an auger may be used and carried atop base12 as appropriate.

In an embodiment, screw conveyor 60 includes a conveyor body 64 and anelongate auger assembly 66. Conveyor body 64 may include a chemicalstorage compartment 67 with an internal hopper 68 that feeds materialinto a lower end of auger assembly 66. Auger assembly 66 includes a tube70 that houses and engages a rotatable auger screw 72. A motor 74selectively rotates auger screw 72 within tube 70, thereby transferringthe material that falls from hopper 68 into the lower end of augerassembly to the upper end of auger assembly 66, where the material isdispensed through a chute 76. An actuator 78 may be included toselectively control the tilt of auger assembly 66.

FIG. 6 is an exploded diagram in perspective view of a quick-disconnectconnector system used with base 12, containers 20, 30, and screwconveyor 60 according to an embodiment. FIG. 7 is a perspective view ofthe quick-disconnect connector system of FIG. 6 in a connected butunlocked state. FIG. 8 is a perspective view of the quick-disconnectconnector system of FIG. 6 in a connected and locked state. Referring toFIGS. 6-8, in one or more embodiments, the quick-disconnect connectorsystem is an ISO twistlock connector. Receptacle 26 forms the femalepart of the connector system and is structurally fitted to the containerframe itself, typically at the corners. Accordingly, receptacle 26 iscommonly known as a corner casting. Receptacle 26 has no moving parts,and it has an oval aperture 27 formed in the bottom.

Connectors 16 are fixed atop mounts 14 of base 12 (FIG. 2). Eachconnector 16 has a fixed stand or pedestal 24. A tapered crown 25 isfixed atop stand 24 so that it may be rotated about an axis 29 throughconnector 16 that is normal to base 14, as indicated by arrow 28 on FIG.6. To carry a container atop base 12, crown 25 is oriented to align withthe major axis of oval aperture 27, and the container is lowered so thatconnector 16 is received within oval aperture 27 as shown in FIG. 7.Next, crown 25 is rotated 90 degrees, so that it will no longer passthrough oval aperture 27, thereby locking the container to mount 14, asshown in FIG. 8.

FIG. 9 is a flow chart that details a portion of a method for completinga well according to an embodiment using chemical transportation,storage, and dispensation system 10 of FIGS. 1-8. The portion of themethod shown in FIG. 9 is particularly useful when hydraulic fracturingoperations are used.

At step 200, a shipping container, which may be an ISO tank 20 (FIG. 3)or van container 30 (FIG. 4), for example, is provided. At step 202, theshipping container is filled with a chemical. At step 204, a base 12(FIG. 2), equipped with a roller at one end and at least a winching padeye or a hook lift hoist attachment at the other end, is provided. Atstep 206, the shipping container is mounted atop the base. Although step202, holding a chemical within the shipping container, is illustrated asoccurring before the shipping container is mounted to the base, in anembodiment the shipping container may be filled with the chemical afterit has been mounted to the base.

Next, at step 208, a transport vehicle is provided. The transportvehicle may have a tiltable bed and a winch or a rack and a hooklifthoist arm. At step 210, the base with shipping container is lifted on tothe transport vehicle. In the case of the transport vehicle having atiltable bed, the bed is first tilted, the winch is connected to thewinching pad eye of the base, the base is winched atop said bed whilethe roller carries at least part of the weight of the base for at leastpart of the winching process, and finally the bed is lowered back to alevel orientation. In the case of the transport vehicle having ahooklift hoist arm, the hooklift hoist arm is connected to the hooklifthoist attachment of the base and the base is hoisted atop the rack ofthe transport vehicle by said hooklift hoist arm while the rollercarries at least part of the weight of the base for part of the hoistingprocess.

At step 212, the base with its mounted shipping container is moved bythe transport vehicle to well site 120 (FIG. 1). At step 214, the baseand its shipping container are unloading from the transport vehicle byessentially reversing the loading process of step 210, and the base andits shipping container are placed on the ground at the well site.

The above process of FIG. 9 may then be repeated until all the requiredchemicals are located at the well site. There, the chemicals held by theshipping containers are readily available for fracturing operationswithout requiring the larger footprint or capital expense of multipletractor-trailers.

In summary, a chemical handling apparatus, a well completion system, anda method for handling chemicals have been described. Embodiments of thechemical handling apparatus may generally have: A generally planar base;a roller rotatively coupled to a first end of the base; at least one awinching pad eye or a hooklift hoist attachment mounted to a second endof the base opposite the first end; and a plurality of mounts coupled tothe base and arranged to securely carry a shipping container atop thebase. Embodiments of the well completion system may generally have: Awellhead atop a wellbore; a fracturing system disposed adjacent to thewellhead and fluidly coupled to the wellbore via the wellhead; and atleast one chemical handling apparatus disposed in proximity to thefracturing system, each of the at least one chemical handling apparatusincluding a generally planar base, a roller rotatively coupled to afirst end of the base, at least a winching pad eye or a hooklift hoistattachment mounted to a second end of the base opposite the first end, aplurality of mounts coupled to the base, and a shipping containercarried atop the base and fixed to the base by the plurality of mounts.Embodiments of the method for handling chemicals may generally include:Providing a shipping container; holding a chemical within the shippingcontainer; providing a generally planar base, a roller rotativelycoupled to a first end of the base, and at least a winching pad eye or ahooklift hoist attachment mounted to a second end of the base oppositethe first end; and mounting a the shipping container atop the base.

Any of the foregoing embodiments may include any one of the followingelements or characteristics, alone or in combination with each other:The shipping container is an intermodal container that conforms toInternational Standards Organization specifications; the plurality ofmounts is dimensioned to accept the shipping container; a connectorcarried atop each of the plurality of mounts for securing the shippingcontainer to the base; a twistlock connector carried atop each of theplurality of mounts and arranged to be received in a corner casting ofthe shipping container for securing the shipping container to the base;a scale coupled to the base and arranged for measuring a weight of theshipping container when carried atop the base; the scale includes atleast one of the group consisting of a strain gauge and a load cell; theshipping container connected to the mounts; the shipping container is a20 foot ISO tank container; the shipping container is a 20 foot ISO vancontainer; a bulk material conveying device connected to the mounts; afirst of the at least one chemical handling apparatus, wherein the firstchemical handling apparatus is characterized by a 20 foot ISO vancontainer, a second of the at least one chemical handling apparatus,wherein the first chemical handling apparatus is characterized by a 20foot ISO tank container; a fracturing blender; a screw conveyer disposedin proximity to the fracturing blender so as to convey a quantity of achemical into the fracturing blender, the screw conveyor being mountedatop a generally planar base, the base having a roller rotativelycoupled to a first end of the base, at least one of the group consistingof a winching pad eye and a hooklift hoist attachment mounted to asecond end of the base opposite the first end; providing a transportvehicle having a tiltable bed and a winch; tilting the bed of thetransport vehicle; coupling the winch to the winching pad eye; winchingthe base carrying the shipping container atop the bed; providing atransport vehicle having a rack and a hooklift hoist arm; coupling thehooklift hoist arm to the hooklift hoist attachment; hoisting the basecarrying the shipping container atop the rack by the hooklift hoist arm;providing a transport vehicle; lifting the base carrying the shippingcontainer on to the vehicle, the roller carrying at least a part of theweight of the base and the shipping container while lifting;transporting the base and the shipping container to a well site; placingthe base on the ground at the well site; placing the base in proximityto a fracturing system at the well site; removing a quantity of thechemical from the shipping container; introducing the quantity of thechemical into the fracturing system; conducting fracturing operations;providing a scale on the base; weighing the shipping container with thescale; determining an amount of the chemical dispensed from the shippingcontainer using the scale; and determining an amount of the chemicalpresent within the shipping container using the scale.

The Abstract of the disclosure is solely for providing the United StatesPatent and Trademark Office and the public at large with a way by whichto determine quickly from a cursory reading the nature and gist oftechnical disclosure, and it represents solely one or more embodiments.

While various embodiments have been illustrated in detail, thedisclosure is not limited to the embodiments shown. Modifications andadaptations of the above embodiments may occur to those skilled in theart. Such modifications and adaptations are in the spirit and scope ofthe disclosure.

What is claimed:
 1. A chemical handling apparatus comprising: agenerally planar base; a roller rotatively coupled to a first end ofsaid base; at least one of the group consisting of a winching pad eyeand a hooklift hoist attachment mounted to a second end of said baseopposite said first end; and a plurality of mounts coupled to said baseand arranged to securely carry a shipping container atop said base. 2.The apparatus of claim 1, wherein: said shipping container is anintermodal container that conforms to International StandardsOrganization specifications; and said plurality of mounts is dimensionedto accept said shipping container.
 3. The apparatus of claim 1, furthercomprising: a connector carried atop each of said plurality of mountsfor securing said shipping container to said base.
 4. The apparatus ofclaim 1, further comprising: a twistlock connector carried atop each ofsaid plurality of mounts and arranged to be received in a corner castingof said shipping container for securing said shipping container to saidbase.
 5. The apparatus of claim 1, further comprising: a scale coupledto said base and arranged for measuring a weight of said shippingcontainer when carried atop said base.
 6. The apparatus of claim 5,wherein: said scale includes at least one of the group consisting of astrain gauge and a load cell.
 7. The apparatus of claim 1, furthercomprising: said shipping container connected to said mounts.
 8. Theapparatus of claim 7, wherein: said shipping container is a 20 foot ISOtank container.
 9. The apparatus of claim 7, wherein: said shippingcontainer is a 20 foot ISO van container.
 10. The apparatus of claim 1,further comprising: a bulk material conveying device connected to saidmounts.
 11. The apparatus of claim 10, wherein: said bulk materialconveying device is an auger assembly connected to said mounts.
 12. Amethod for handling chemicals, comprising: providing a shippingcontainer; holding a chemical within said shipping container; providinga generally planar base, a roller rotatively coupled to a first end ofsaid base, and at least one of the group consisting of a winching padeye and a hooklift hoist attachment mounted to a second end of said baseopposite said first end; and mounting a said shipping container atopsaid base.
 13. The method of claim 12, further comprising: providing atransport vehicle having a tiltable bed and a winch; tilting the bed ofsaid transport vehicle; coupling said winch to said winching pad eye;and winching said base carrying said shipping container atop said bed.14. The method of claim 12, further comprising: providing a transportvehicle having a rack and a hooklift hoist arm; coupling said hooklifthoist arm to said hooklift hoist attachment; and hoisting said basecarrying said shipping container atop said rack by said hooklift hoistarm.
 15. The method of claim 12, further comprising: providing atransport vehicle; and lifting said base carrying said shippingcontainer on to said vehicle, said roller carrying at least a part ofthe weight of said base and said shipping container while lifting. 16.The method of claim 15, further comprising: transporting said base andsaid shipping container to a well site; and placing said base on theground at said well site.
 17. The method of claim 16, furthercomprising: placing said base in proximity to a fracturing system atsaid well site; removing a quantity of said chemical from said shippingcontainer; introducing said quantity of said chemical into thefracturing system; and conducting fracturing operations.
 18. The methodof claim 12, further comprising: providing a scale on said base; andweighing said shipping container with said scale.
 19. The method ofclaim 18, further comprising: determining an amount of said chemicaldispensed from said shipping container using said scale.
 20. The methodof claim 18, further comprising: determining an amount of said chemicalpresent within said shipping container using said scale.
 21. A wellcompletion system comprising: a wellhead disposed atop a wellbore; afracturing system disposed in proximity to the wellhead and fluidlycoupled to the wellbore via the wellhead; and at least one chemicalhandling apparatus disposed in proximity to the fracturing system, eachof said at least one chemical handling apparatus including a generallyplanar base, a roller rotatively coupled to a first end of said base, atleast one of the group consisting of a winching pad eye and a hooklifthoist attachment mounted to a second end of said base opposite saidfirst end, a plurality of mounts coupled to said base, and a shippingcontainer carried atop said base and fixed to said base by saidplurality of mounts.
 22. The well completion system of claim 21, furthercomprising: a first of said at least one chemical handling apparatus,wherein said first chemical handling apparatus is characterized by a 20foot ISO van container; and a second of said at least one chemicalhandling apparatus, wherein said first chemical handling apparatus ischaracterized by a 20 foot ISO tank container.
 23. The well completionsystem of claim 21, further comprising: a fracturing blender; and ascrew conveyer disposed in proximity to said fracturing blender so as toconvey a quantity of a chemical into said fracturing blender, said screwconveyor being mounted atop a generally planar base, said base having aroller rotatively coupled to a first end of said base, at least one ofthe group consisting of a winching pad eye and a hooklift hoistattachment mounted to a second end of said base opposite said first end.